2 Big Broncos 4x4 Technical White Papers

Members and associates of the 2-Big Broncos 4x4 club have written the
materials contained on these pages. Authors offer no guaranties
on the usefulness or accuracy of the writings. Authors and the
2-Big Broncos 4x4 Club are not responsible for any information or
actions taken by you for using this information.

Take this information for "face value" and use with your own discretion and wisdom.

Description and Reasoning

Why an engine and transmission conversion?

After running many, many miles to Colorado and back in July 2000; Working with the altitude and carburetor adjustments at 10-13,000 feet, experiencing fuel "vapor lock" problems, having fuel splash around on many of the trails, and my second "daily driver" Bronco's engine was dying very quickly... I went ahead with the purchase of a "parts yard" 1996 Ford Bronco with 36k miles. Ended out this Bronco had a good engine, transmission, and most of the OBD-II sensors still in tack. Could not pass up this purchase / upgrade! Also, the transmission in my Bronco was beginning to over-heat in normal driving conditions - as a result from the Colorado return trip I assumed.

The E40D automatic should make this conversion eaiser with the electronics feeding the PCM ("Computer"). Also, the E40D has ... the electronic push-button over-drive and a wide-ratio gear set!! This gives me a lower 1st and 2nd gear for off-road crawing, a high ratio over-drive for highway speeds when I change my ring/pinion from 4.10 to 4.56 in the future. I can have my "cake" and eat it too. I know of a few issues to deal with on the E40D during the conversion.

Physically at least 3" longer the my stock C-6 transmission

Linkage is cable based rather then my stock levers

Oil pan is hugh with a rather large oil sump area -- will need some custom rock protection

Removing "WildHorses" 351W HO Motor - September 12, 2000

This motor was rebuild in 1992, about 45,000 miles ago. The power and oil pressure have been great. I am replacing the leaky rear main seal (2 piece) and oil pan gasket before installing it into my second 1986 Bronco. The daily driver...

Rade is ready and waiting

Just about removedA very high pull up

Finished... almost.Now for the rear main seal

Replacing the leakyrear main seal

On this motor, it isa two piece seal

To service this sealthe bearing caps areloosen and the rearhas been removed

Finished the engine swap into my "Mr Blue" Bronco on September 22, 2000. Now I can focus on the R-E-A-L work at hand!!!!

Ready to Start

On recommendations from my local "EFI Experts", I purchased a few reference materials. These books are considered the best of the best by content and authors.

Inspection and Installation of 351EFI Motor

January 20, 2001

Following a long break-away from the shop, Rade got me started again on Saturday, January 20. He and I replaced the upper intake gasket, throttle body gasket, and both valve cover gaskets. The rear main seal was inspected and decided to keep in place. Motor was the hoisted over and into the Bronco. With no transmission, the insert too two minutes (once we removed the hood).

Upper intake gasket - replacement

Throttle body gasket - replacement

EGR gasket - High temperature Silicone

Valve cover gaskets - replacement

Rear main seal - inspected and kept

Motor mounts - replaced

Valve cover removedshowing excellantcondition of motor.

Upper intake removed.

Inspected rear main sealand kept it un-touched.

The 351EFI motoris now in!

Looking real cool.Needs wiring and much more!

Fuel Tank Low-Pressure PumpApril 2001

Another small side-project is the fuel system feeding the injected 351W motor. My choice was to install a low-pressure feeder pump (in the tank) to a frame-rail high pressure pump feeding the engine's fuel rail. I picked up a used high-pressure pump and miscellaneous wirings and fuel lines from a parts-yard.

I had already made a fuel tank purchase from MTS Company, L.C. Model #4251S which had the correct access hole for a 1987 EFI fuel system. I needed the sending unit, low-pressure pump, and wiring to activate the fuel pump.

Wiring to feed the in-tanklow-pressure fuel pump.

Filler tube andbreather tube.

Installed with returnline in view.

High pressure pump attachedto frame rail.

OBD-II Computer Brains(PCM)April 2001

A "big deal" sub-project is the computer module for which all OBD-II processing gets handled. I was able to pickup the PCM and wiring harness along with the engine, from the same vehicle.

The location was not much of a choice. Basically the wiring harness REQUIRED me to locate the PCM in the firewall, next to the brake master cylinder. This work required serious cutting, fabricating, sealing and rivet work. I would rather have purchased an injected Bronco before doing this again... something to consider.

I removed the fender tocreate easy accessto my work area

Mark the locationof the PCM boxbefore cutting.

Cut and re-enforcedwith rivets.

Container box installedand PCM with my customcover ready.

Finished. Is thisready for water?

Final look...

July 7, 2001

This was taken shortly before leaving for Northwest BroncoFest 2001 in Kaner Flats campground. It worked great.

January 27, 2001

The E40D was a simple bolt-in on this motor, except for modifications to the cross-member bracket and usage of the C6 transmission mount. This custom setup using a C6 transmission mount and cross-member bracket (from the 1986 configuration) required (REQUIRED!) my 1" body lift for clearance. It fit, but with only 1/2" space between the body and transfer case.